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Sakai GW75O Operating & Maintenance Instructions

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OPERATING
MAINTENANCE
INSTRUCTIONS
VIBRATIN
G
ROLLE
R
&
MODEL
GW75O
SAKAI
No.
3498-35690-2
From VGW1 - 10102

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  • Page 1 3498-35690-2 Read this handbook thoroughly and understand the whole information contained before trying to operate, inspect and service your machine! OPERATING & MAINTENANCE INSTRUCTIONS MODEL GW75O VIBRATIN ROLLE From VGW1 - 10102 SAKAI...
  • Page 2 PREFACE PREFACE This operator's manual serves as a guide for the use of your Sakai GW750 Vibrating Roller for those who are new to the machine, and also for the people who have experience in using the Machine and want to refresh their knowledge for the machine.

  • Page 3: Table Of Contents

    CONTENTS CONTENTS PREFACE MACHINE AND ENGINE IDENTIFICATION NUMBERS ......... 1 SAFETY NOTICES ....................,; 2 1. BASIC PRECAUTIONS FOR SAFETY ............... 4 1.1 General Precautions ..................1.2 Preparation for Safe Operation ............... 6 1.3 Before Starting the Engine ................7 1.4 After Starting the Engine .................
  • Page 4 CONTENTS Sprinkler ....................36 Liquid Sprayer ..................39 Precautions for Work ................41 2.7.1 Compaction operation ..............41 2.7.2 When going downhill ............... 41 2.7.3 On a slope ..................41 Applicable Jobs ..................42 After Operation ..................42 2.10 Loading and Unloading ................43 2.10.1 Use of a trailer equipped with a winch ..........

  • Page 5: Machine And Engine Identification Numbers

    When ordering parts or making inquiries about your machine, the following information is requested: (1) Machine model Indicated on the dashboard in the operator's station. MODEL CHASSIS No SAKAI HEAVY INDUSTRIES, LTD. Toicro.mova. (2) Machine serial number GW750 > VGW1 – 0 0 0 0 0 Location...

  • Page 6: Safety Notices

    SAFETY NOTICES SAFETY NOTICES For the safe use of your machine, correct handling and periodical maintenance are of utmost importance. Thoroughly read the safety precautions described in this manual. Do not attempt to operate and maintain your machine until you gain a full understanding of these safety statements.
  • Page 7 * Non-approved modifications can pose safety-related problems. Before making any modifications, consult your distributor. For an injury or damage to the machine caused by non-approved modifications, Sakai accepts no responsibility. * Basic precautions for safe operation of your machine are discussed beginning on page 4. *...

  • Page 8: Basic Precautions For Safety

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY 1. BASIC PRECAUTIONS FOR SAFETY 1.1 General Precautions ◼ Read thoroughly the operator's manual. • Understand the functions of the controls and gauges. Familiarize yourself with their location and how to operate them.
  • Page 9 WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Do not use a machine which has not been serviced correctly at regular intervals. • Before working, perform necessary inspections. Start operation only after making certain the machine is in good operating condition.

  • Page 10: Preparation For Safe Operation

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Mount on or dismount from your machine after it has come to a complete stop. • For getting on and off, face the machine and use the handrail and step. •...

  • Page 11: Before Starting The Engine

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Know the stopping distance. • When traveling on a road, bear in mind the stopping distance. Avoid excessive speed, and abrupt starting and stopping, and moving in a zigzag direction. 1.3 Before Starting the Engine ◼...

  • Page 12: After Starting The Engine

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Pay attention to ventilation. • Exhaust fumes are dangerous if breathed in. When starting the engine in an enclosed area, provide good ventilation with windows and doors opened. ◼...
  • Page 13 WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Do not try to get on or off a moving machine. • Get on or off the machine after making sure it has come to a complete stop. ◼...

  • Page 14: Loading And Unloading

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Do not operate the machine except from the operator's seat. Do not drive in a standing posture. ◼ While making turns, do not run at abnormally high speed and do not turn the steering wheel abruptly and sharply.

  • Page 15: Transportation

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY • To prevent your machine from crosswise slippage, keep the ramps free from oil, mud, debris, etc. The drum must also be free from extraneous matter that can cause slippage. •...

  • Page 16: Towing

    WARNING: Negligence of these instructions can lead to accidents. I. BASIC PRECAUTIONS FOR SAFETY • Inspect or handle the battery with the engine shut down and the starter key in the OFF position. • Keep metallic items such as tools away from the battery terminals.

  • Page 17: Before Servicing

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY 1.10 Before Servicing ◼ Attach warning tags when servicing the machine. • Serious accidents can occur if the machine is unexpectedly started or controls carelessly touched by an unauthorized person. •...

  • Page 18: During Servicing

    WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Supplying fuel and oils • Spilled fuel or oil will be slippery. Wipe up immediately. Keep the filler caps tight. Do not use fuel for flushing oil. Handle fuel and oil in a well ventilated area. ◼...
  • Page 19 WARNING: Negligence of these instructions can lead to accidents. 1. BASIC PRECAUTIONS FOR SAFETY ◼ Be careful of high pressure hydraulic fluid. • Bear in mind that the working equipment hydraulic systems are under internal spressure. Do not perform adding, draining, inspection or servicing of the hydraulic systems until the internal pressure has been relieved.

  • Page 20: Safety Decals

    2.Preparation for Safe Operation © 3998-16502-0 -Clean the steps, operator's station and floorboards. 'Obey the worksite rules. 'Sakai accepts no responsibility for any injury or damage 1 557-1 9006-1 to the machine caused by unapproved modification. DANGER • Do not use a machine which needs repair or •...
  • Page 21 WARNING: Negligence of these instructions can lead to accidents 1. BASIC PRECAUTIONS FOR SAFETY —17—...

  • Page 22: Operation

    2. OPERATION 2. OPERATION 2.1 Instruments and Controls 2.1.1 Operator's station (o Forward-Reverselever (F-R lever) Sprinkler timer w i t h v i b r a t o r s w i t c h ©Vibrator switch ()Steering wheel Vibration indicator LAMP ®...

  • Page 23: Gauges, Indicator Lamps And Warning Lamps

    2. OPERATION 2.1.2 Gauges, indicator lamps and warning lamps For safe execution of your job, fully understand the role and function of the systems involved. Combination mater Monitor display Tachometer u6557.:tz,g0 .et? ocrofTgo Fuel gauge Temperature gauge Hour meter Tachometer / Hour meter Indicates the engine RPM.
  • Page 24 2. OPERATION Monitor display Turn signal indicator lamp Flashes when turn signal lever is moved. Hydraulic oil filter warning lamp —Engine oil pressure warning lamp Goes on when filter is clogged. Goes on when engine lubricating oil pressure is lowered below specified value. Battery charge lamp ___ Parking brake indicator Goes on when troubles...

  • Page 25: Switches

    2. OPERATION 2.1.3 Switches Starter switch Starts and stops the engine. HEAT: When the engine is cold, hold the starter switch in the HEAT position, the heater indicator lamp will go on. Stay in that position until the indicator lamp goes off. Release the switch key when the indicator lamp goes off.
  • Page 26 2. OPERATION Flood lamp switch The flood lamps at the rear of machine light up with fitted the indicator lamp [..9] on the monitor display coming on when switch 0 is pressed down. The lamps come off if the switch is pushed down again. OFF —...
  • Page 27 OPERATION Horn switch Pressing the button at the center of the steering wheel makes the horn sound. Vibrator switch Turns on/off vibration ON-OFF and changes vibration amplitude. S wit ch in g f rom 1 to 4 cau se s vib rat ion at h ighe r amplitude.
  • Page 28 2. OPERATION Sprinkler switch/Sprnkler timer The sprinkler switch and sprinkler timer are both used for sprinkler operation. Sprinkler switch selects continuous sprinkling, and intermittent sprinkling. Switch selects the sprinkler modes. Sprinkler switch : Continuous sprinkling is performed. OFF : Sprinkling is shut off. INT.
  • Page 29 2. OPERATION Uphill / Flat selector switch for sprinkling Switches the sprinkling piping route. "SLOPE" switch is SLOPE LEVEL for uphill slope, and "LEVEL" switch is for flat road. GW750 is equipped with one sprinkler pump, and water in the front and rear sprinkler tanks is simultaneously supplied to the pump.

  • Page 30: Operating Levers And Pedals

    2. OPERATION 2.1.4 Operating levers and pedals Forward-reverse lever (F-R lever) with vibrator switch Moving the F-R lever forward or backward makes the Vibrator  machine travel forward or backward respectively. The O N / O F F neutral position brings the machine to a stop. The vehicle "'s For war d speed increases or decreases in proportion to the lever 0 Neutral...

  • Page 31: Unloader Valve

    OPERATION Brake pedal In an emergency, push down on the pedal to the full extent, and the machine will come to a sudden stop. T NT Do not use the pedal wherever practicable except for an emergency. If used during the compacting operation of ashalt pavement, this can cause damage to its surface.

  • Page 32: Fuse Box

    2. OPERATION 2.1.6 Fuse box WARNING When changing a fuse, cut the power supply by turning the starter switch to the OFF position. Fuses protect electrical components and wiring 20 A uk 1 -..._ from burning. Change any fuse which has -..„---..., --, 15 A become powder-coated due to deterioration or...

  • Page 33: Seat Adjustment

    2. OPERATION WARNING _________________________________________________________ • When the awing is folded, loosen the fixing bolt, unlock the lock pin, then fold the supporting columns forward after making sure the damper to permit easy column lifting is functioning. • If the damper is not working use care because the supporting columns can fold forward quickly.

  • Page 34: Operation

    2. OPERATION 2.3 Operation ___ A WARNING This machine is a one-man roller. Operate the machine from the operator's seat. 2.3.1 Before-starting inspection 1) Check that the steering lock bar is in the carrying position. WARNING Make sure that the steering lock bar is connected in the carrying position before putting the machine in motion.

  • Page 35: Starting The Engine

    OPERATION 2.3.2 Starting the engine __ WARNING __________________________________________________________ Check that the F-R lever is in the neutral position, and sound the horn when starting the engine after making certain that there are no one and no objects close to the machine. 1) Set the throttle lever in a position slightly higher than IDLING.

  • Page 36: After Starting The Engine

    2. OPERATION 4) Turning the key to the START position makes the engine start. Release the key the moment the engine has started. The key will automatically return to the ON position. CAUTION ________________________________________________________ • Do not allow the starter key to stay in the START position for more than 15 seconds.

  • Page 37: Traveling

    2. OPERATION 2.3.4 Traveling A CAUTION While travelling, do not turn the starter switch OFF. A WARNING ____________________________ When starting, operate the horn after securing the safety around the machine. Clear away obstacles on the road. )1 2nd 1) Select the desired speed by the operation of speed shift lever. Speed shift lever Speed shift lever Travel speed...

  • Page 38: Stopping / Parking

    2. OPERATION 4) Move the F-R lever in the direction to travel, and the. machine will begin traveling. CAUTION Avoid abrupt operation of the F-R lever. ® Forward 0 Neutral NOTE: The travel speed can be controlled by the throttle ®...

  • Page 39: Stopping The Engine

    2. OPERATION 2.3.6 Stopping the Engine 1) Gradually cool down the engine at low idling for about 5 minutes IMPORTANT • Do not bring a hot engine to a sudden stop except for an emergency. This will shorten the life of its component parts. •...

  • Page 40: Vibratory Operation

    2. OPERATION 2.4 Vibratory Operation 1) Run the engine at 1,800 rpm or higher by operating the _______ throttle lever. OFF< —4 2) Switching from 1 to 4 causes vibration at higher amplitude. Vibration 1 operates even in stop state if the engine speed is 1,800rpm or higher, but vibration 2 to 4 operates only while moving forward or backward.
  • Page 41 2. OPERATION • The table below serves as a guide for sprinkling and idling durations. Vehicle speed Sprinkling duration Idling duration (km/h) (seconds) (seconds) 2 (1.2 mile/h) 7 - 8 35 - 40 3(1.9 mile/h) 4 - 5 3 0 3 5 35 4 (2.5 mile/h) 3 - 4 25 - 30...
  • Page 42 2. OPERATION Sprinkler Sprinkler Filter \pump (Drain valve) (Drain valve To drain water: Turn sprinkler tank drain cap counter-clockwise and completely drain the tank. ©Completely drain the sprinkler pump, filter, and pipes by removing valves ©, Drain the front and rear sprinkler bars by opening value ®. ®...

  • Page 43: Liquid Sprayer

    OPERATION 2.6 Liquid Sprayer 1) Before spraying, check for the liquid level in the tank with the sight gauge. Add liquid as necessary. CAUTION Driving the liquid spray pump with the liquid tank empty will damage the pump. Pay attention to the liquid level in the tank.
  • Page 44 2. OPERATION Adjusting spread of nozzle When the liquid is sprayed to the tire, the spread of the nozzle should be adjusted so that the liquid will be applied within the tire width. The spread of the nozzle is adjusted with the round handle of the valve located at the liquid valve end of the front/rear tires.

  • Page 45: Precautions For Work

    2. OPERATION 2.7 Precautions for Work 2.7.1 Compaction operation ◼ Rolling compaction of asphalt • For asphalt compaction, use amplitude 1 or 2. ◼ Change the direction of travel gently. • When changing the direction of travel during asphalt mix compaction, slowly shift the F-R lever.

  • Page 46: Applicable Jobs

    2. OPERATION 2.8 Applicable Jobs The machines do avariety of jobs as listed below: Work • Asphalt road paving • Dust removal treatment for road • Road improvement • Embankment construction • Dam construction • Construction of forestry and farm roads •...

  • Page 47: Loading And Unloading

    2. OPERATION RTA NT Insufficient draining of water can cause troubles or damage to the system. 2.10 Loading and Unloading WARNING __________________________________________________________ • Use sturdy ramps with proper width, length and thickness which allow safe loading and unloading. • If the ramps deflect considerably under load, apply wooden blocks to reinforce them.

  • Page 48: Self-Propelling

    2. OPERATION 3) Draw the wire rope from the trailer winch and put its © hook on the hooking point or © of the roller. 4) Place the unloader valve located at the operator's station to the UNLOAD position (See "Unloader valve" on page 27).

  • Page 49: After Loading The Machine

    OPERATION 2.11 After Loading the Machine When the machine has been located properly on the trailer, tie it down as follows: 1) Press the parking switch button to apply the parking brake. Place wooden blocks under the drums to prevent movement. 2) Fix the machine with ropes tied at the front and rear towing hook holes.

  • Page 50: Coolant

    2. OPERATION 2.13.2 Coolant W A R N I N G Do not bring an open flame to the untifreeze or do not smoke when handling it. It is inflammable. __ CAUTION _____________________________________ Never use methanol-, ethanol- and propanol-base antifreeze. Use soft water for coolant.

  • Page 51: Battery

    2. OPERATION 2.13.3 Battery ___ WARNING ______________________________________________________________________ • Batteries generate explosive gases. Do not use an open flame close to batteries. • The battery electrolyte is corrosive. Keep the electrolyte away from your eyes and skin. If you are affected by the electrolyte, flush with large quantities of water and get medical help.

  • Page 52: When The Cold Season Is Over

    OPERATION 2.14 When the Cold Season is Over When winter is over and the warm season has come, proceed as follows: 1) Change oil and fuel with those for use in warm season referring to "Rating" on page 66. 2) If AF-PT antifreeze is in use, drain the coolant completely, wash clean inside the cooling system, and then fill with clean water (city water).

  • Page 53: When The Battery Has Discharged

    2. OPERATION 2.17 When the Battery Has Discharged WARNING • To check and handle the batteries, keep the Disconnect with negative cable first engine stopped with the starter switch in the OFF position. • The batteries give off explosive gases. Do not smoke close to the batteries.
  • Page 54 2. OPERATION ◼ Disconnection of booster cables 1) Disconnect the negative booster cable ® from the engine block earth. 2) Disconnect the negative booster cable from the booster supply. 3 Disconnect the positive booster cable from the Booster supply B a t t e ri es of t he booster supply.

  • Page 55: Periodical Maintenance

    General precautions: (1) Always use Sakai genuine parts for replacement. (2) Use lubricants recommended by Sakai. Avoid mixing different brand lubricants. (3) For hydraulic oil replenishment, changing, level checking, filter cleaning or replacement, oiling and greasing, use extreme care to prevent dust from entering.
  • Page 56 PERIODICAL MAINTENANCE Replacement System or Periodical replacement Part name Remarks period maintenance parts Mechanism Master cylinder Seals (rubber parts) 2 years Adopted machines only Wheel cylinder Seals (rubber parts) 2 years 1. Brake system Brake hose 2 years Brake piping parts Air hose 2 years Adopted machines only...

  • Page 57: Walk-Around Checking

    PERIODICAL MAINTENANCE 3.2 Walk-Around Checking For efficient operation, daily, before-operation checking is very important. Before starting, perform walk-around checking for loose bolts, nuts and signs of leakage in addition to items as shown below: tires: Sprinkler tank: Hub bolt looseness Water lever Engine: Oil leakage...

  • Page 58: Periodical Maintenance Points

    PERIODICAL MAINTENANCE 3.3 Periodical Maintenance Points 54 -...
  • Page 59 PERIODICAL MAINTENANCE Interval Item Service Ref. Lubricant Q'ty © Diesel oil Every 10 Fuel tank Check fuel level, add as necessary hours or Radiator Coolant Check coolant level, add as daily necessary ® Check oil level, add as necessary Engine oil Engine oil pan ©...

  • Page 60: Maintenance Procedure

    PERIODICAL MAINTENANCE 3.4 Maintenance Procedure For servicing the engine, see the separate engine manual. (1) Every 10 hours or daily Fuel tank Check the fuel level with the fuel gauge or the level gauge. Add as necessary from fill hole. CAUTION For refueling, park the machine on a level and solid surface.

  • Page 61: Every 50 Hours

    PERIODICAL MAINTENANCE (2) Every 50 hours Fuel sedimenter Check the float level. If it comes up to the warning mark, Float lever take off the plug at the bottom and drain water. Drain plug Hydraulic tank Check the oil level with the sight glass on the side of tank. The level is proper if it is between H and L marks.

  • Page 62: Every 250 Hours

    PERIODICAL MAINTENANCE Sprinkler filter 1 1 1 1 1 1 1 / h r 4 Take off the filter case by turning counter-clockwise as __________--7◼Nort!f 40 11 liftriliillki,, t g ai mi v e ri , t viewed from the bottom. Clean the element. ..=,------.--c..., II/ P A , I I I I N 1 1 % - l i r n...
  • Page 63 PERIODICAL MAINTENANCE Power distributor Check oil and add if necessary. Fan belt Replace as 0 Check the fan belt for wear and damage. necessary. ()Check the tension. Depress the middle of a the belt with push of about 10kg. A properly adjusted belt deflects 10 to 15 mm.
  • Page 64 PERIODICAL MAINTENANCE Vibrator Check for the oil level and leakage. tires 1) Check for unusual wear and damage. 2) Check for the inflation pressure. (4.5 kg/cm2) 3) Check the wheel nuts for looseness. Tilt bearing Center pin Tilt bealing Grease lubricate two locations. Center pin Grease lubricate two locations.

  • Page 65: Every 500 Hours

    3. PERIODICAL MAINTENANCE Wheel hub nut Check the wheel hub nut for looseness. If it is loose, tighten it. Be sure to torque it to the specified value. Tightening torque: 265 N • Lll CAUTION _______________________________________________________ • Turn the wheel hub nut in the tightening direction during inspection. •...

  • Page 66: Every 1000 Hours

    PERIODICAL MAINTENANCE Control link Remove the operator seat floor cover and the cover under the dashoboard. Check the bolts and nuts for looseness. Adjust the rod. Liquid spray strainer uid tank cover Take off the liquid tank cover. Take out and clean the strainer, change the strainer if necessary.
  • Page 67 PERIODICAL MAINTENANCE Power distributor 1) Drain the power distributor oil by removing the drain plug. 2) Refit the drain plug. 3) Take off the level plug and fill port plug. 4) Fill oil through the fill port until oil starts overflowing from the level port.

  • Page 68: As Required

    PERIODICAL MAINTENANCE (6) As required Sprinkler tank 1) Remove the drain cap under the sprinkling tank located at the machine front/rear discharge dust and deposit in the tank. 2) Remove the filler cap and clean the interior of the tank. 3) When the necessary work is complete, refit the drain cap and filler cap.
  • Page 69 PERIODICAL MAINTENANCE Fuel tank 1) With the drain plug removed, remove the water and sediment from the bottom of the tank. 2) If sedimentation is substantial, remove the drain plug and clean the interior of the tank. 3) When the necessary work and refueling are complete, tighten the filler cap positively.

  • Page 70: Feeding Water And Lubricants

    PERIODICAL MAINTENANCE 3.5 Feeding Water and Lubricants 1. General rules 1) Never feed water or lubricant with the strainer removed. 2) Use recommended lubricant and hydraulic fluid. 3) Do not use lubricants and hydraulic fluid of different brands. 4) When replacing oil, drain it completely and clean the container with flushing oil before filling new oil.
  • Page 71 PERIODICAL MAINTENANCE 4. Recommended lubricants Lubricant Engine oil Gear oil Hydraulic oil Grease (NLGI – II) API – CC API GL 4 VG 46 company CALTEX Martifack RPM DELO Universal Rando Oil 300 oil Thuban 90 HD 46 EP 2 BP Vanellus BP Energol BP Energrease...

  • Page 72: Electric Wiring Diagram

    TURN SIGNAL LAMP(R) (26W) VIBAUTO2' RELAY (7).. VIBAUTO SWITCH SIDE MARKER VIB.MOTOR LAMP (10W) RELAY HONE THROTTL HORN VIE. F-R LEVER SWITCH (R),(L) WATER SPRAY RELAY TIMER 1 & (FRONT) WATER SPRAY RELAY INC31 WATER SPRAY VIB.SOL = HEADLAMP FUSE I — / PUMP (REAR)_ 75/70W...
  • Page 73 PERIODICAL MAINTENANCE Fuse box The fuse box houses five 15A-, three 20A-, and two 30A- fuses lined up with spares fitted for 15A-, 20A- and 30A- fuses. Use fuses of correct capacity. See page 28. NOTE: When a fuse is burned, determine the cause befor replacing. Battery ...

  • Page 74: Specifications

    4. SPECIFICATIONS 4. SPECIFICATIONS GW750 Vibrating power: Model Centrifugal force 1 st 7.8kNI800kgfl 3 rd 41.9kN 14,270kgfl Weight: 2 nd 24.5kNI2,500kgfl 4th 58.4kN {5,960kgf} Gross weight 9,000 kg (19,841 lbs) Empty weight 8,400 kg (18,519 Ibs) Gradability 21 degrees Dimension: Rolling width 1,950 mm (77") Overall length...
  • Page 75 SAKAI HEAVY INDUSTRIES, LTD. Head Office: 1-4-8, Shiba Daimon, Minato-ku, Tokyo, Japan Telephone: Tokyo (03) 3431-9971 Facsimile: (03) 3436-6212 Printed in Japan 2006. 01. 9000...
  • Page 76 SAKAI HEAVY INDUSTRIES, LTD.

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